Hypro 5321C-D User manual

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Model Number: 5321C-D
Hypro 5321C-D Pump Twin Plunger With Chemical Injector Head 1000psi
Manufacturer: Hypro Pumps
Hypro 5321C-D Small Twin Plunger Pump with injector head, 2.2 GPM @ 1000 PSI
@ 1800 RPM, Cast iron pump with base and Buna-N seals, 5/8" OD solid shaft, 1/2"
NPT ports, 190 deg. max. temp., Plunger material: Stainless Steel, 11 lbs.
Receive half price shipping if picking up at SteamBrite Supply
Owners Manual
More stuff: (may not all fit on web page)
Installation, Operation, Repair And Parts Manual
07/06
Description
Series 5300C-X, 5321C, 5322C and 5324C
Small Twin® Piston and Plunger Pumps Form L-0200P
The following special attention notices are used to notify
and advise the user of this product of procedures that
may be dangerous to the user or result in damage to the
product.
NOTE: Notes are used to notify of installation, operation,
or maintenance information that is important
but not safety related.
CAUTION: Caution is used to indicate the presence
of a hazard, which will or can cause minor injury or
property damage if the notice is ignored.
WARNING: Warning denotes that a potential hazard
exists and indicates procedures that must be followed
exactly to either eliminate or reduce the hazard,
and to avoid serious personal injury, or prevent
future safety problems with the product.
DANGER: Danger is used to indicate the presence
of a hazard that will result in severe personal injury,
death, or property damage if the notice is ignored.
Safety Information
SERIES 5321C & 5322C
Cast Iron Small Twin
Plunger Pump
Max. Flow Rate: ........................2.2 gpm
Max. Pressure: ........................1000 psi
Max. Speed: ............................1725 rpm
Ports:................................1/2" NPT inlet
1/2" NPT outlet
Max. Operating Temp.................180o F
SERIES 5300C-X
Cast Iron Small Twin
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Piston Pump
SERIES 5324C
Cast Iron Small Twin
Piston Pump
Max. Flow Rate: ........................2.9 gpm
Max. Pressure: ..........................800 psi
Max. Speed: ............................1725 rpm
Ports:................................1/2" NPT inlet
1/2" NPT outlet
Max. Operating Temp.................140o F
Max. Flow Rate: ..................1.5, 2.0, 2.5
and 3.0 gpm
Max. Pressure: ..........................500 psi
Max. Speed: ............................1725 rpm
Ports:................................1/2" NPT inlet
1/2" NPT outlet
Max. Operating Temp.................140o F
DANGER: DO NOT pump flammable or explosive
fluids such as gasoline, fuel oil, kerosene, etc. DO
NOT use in explosive atmospheres. The pump
should be used only with liquids compatible with the
pump component materials. Failure to follow this
warning can result in personal injury and/or property
damage and will void the product warranty.
A pressure relief device, such as an unloader, relief
valve or balancing regulator must be installed on the
outlet side of the pump. Failure to do so could
result in personal injury and/or void the warranty.
• Be sure all exposed moving parts such as shafts,
couplers and adapters are properly shielded or
guarded and that all coupling devices are securely
attached before applying power.
• Hollow shaft pumps mounted directly onto power
shaft must be prevented from rotating with the
power shaft by means of a device such as a torque
arm. Pump must float freely on the power shaft and
must not be tied rigidly to equipment on which it is
mounted.
-2-
• Do not exceed recommended speed, pressure
and temperature for pump and equipment being
used.
• Before servicing, disconnect all power, make sure
all pressure in the system is relieved, drain all liquids
from the system and flush.
• Secure the discharge lines before starting the
pump. An unsecured line may whip, causing personal
injury and/or property damage.
• Check hose for weak or worn condition before
each use. Make certain that all connections are
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tight and secure.
• Periodically inspect the pump and the system
components. Perform routine maintenance as
required (see Maintenance section).
• Protect pump from freezing conditions by draining
liquid and pumping rust inhibiting solution, such as
antifreeze, through the system, coating the pump
interior.
• Use only pipe, hose and fittings rated for the maximum
(or greater) PSI rating of the pump.
• Do not use these pumps for pumping water or
other liquids for human or animal consumption.
Drive Source Installation
This manual will cover the installation of the basic drive
configurations available for the Hypro Small Twin
Piston and Plunger pumps. Consult the manufacturer
of your motor or engine for additional information.
Read all instructions and general safety information
before attempting to install or operate the pump.
Belt/Pulley Drive Installation
Mounting Belts and Pulleys
Mount pulleys as close to pump and motor engine shaft
bearings as possible. Check alignment with a straight
edge as shown (See Figure 1). Make sure that belt has
proper tension. (Too much tension will cause bearing
wear; too little will cause slippage.) (See Figure 2). Check
with belt and pulley sources for specific recommendation.
To figure proper diameter of pump pulley, multiply
motor/engine RPM by diameter of the motor/engine pulley
and divide that figure by desired pump speed.
Pump = Motor RPM x Motor Pulley Size
Pulley Size Desired Pump Speed
Refer to pump performance charts to determine desired
speed to obtain desired maximum flow.
NOTE: Shaft rotation can be either clockwise or counterclockwise.
Push the belt midway
between the
pulleys, check the
deflection (d) and
adjust:
d = 0.016 x L
Four points of
contact indicate
alignment.
NOTE: Pump may
be mounted in other
orientations with
respect to the motor
or engine.
Figure 1
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Figure 2
Direct Drive - Flexible Coupling Installation
First, slide coupling ends onto motor/engine and
pump shafts as far as possible (See Figure 3).
Mount motor/engine and pump onto base, shimming
pump or power unit so that shafts are aligned.
Leave enough space between ends of shafts to
allow coupling disc to be inserted. When alignment
is made, slide coupling ends over coupling disc.
Leave clearance between coupling ends and center
disc. Tighten screws in both coupling ends. For
electric motor drive, use couplings rated at least
twice the horsepower required to operate pump. For
gas engine drive, select couplings rated at three
times the required pump horsepower.
CAUTION:
For safety, always install a
shield over rotating shafts
and couplings.
Figure 3
L
d
-3-
IN OUT
Direct Drive - Hollow Shaft Installation
Hollow shaft models mount directly on the motor or
engine shaft (See Figure 4). Adapters are available to
convert some solid shaft models for direct shaft mounting.
After mounting the pump, always turn it by hand
to make sure the pump is operating freely. Never
apply power to a pump that appears to be stuck.
CAUTION: Use a torque arm to keep the pump
from rotating with the shaft. The pump must be
allowed to float on the shaft and must not be tied
rigidly to the equipment on which it is mounted.
CAUTION:
For safety, always install a shield
over rotating shafts. Or enclose
the pump/motor assembly inside
a housing.
Figure 4
System Installation
Figure 5
Piston Pump Installation
Accessories should be installed with solid piping and be
mounted as close to the pump as possible. The hose must
be used right after accessories.
NOTE: If remaining installation is solid piping, a two to
four foot length of hose must be installed between
accessories and solid piping.
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Hose
Selection of the right size and type of hose is vital for good
performance. Be sure to hook up to the proper ports on the
pump (note markings “IN” and “OUT” on pump castings).
Suction Hose
Always use genuine suction hose compatible with the fluids
being pumped and at least the same inside diameter as
pump ports. If the suction hose is over 5 feet long, use the
next larger size hose. Keep the suction hose as short as
possible and restrictions such as elbows, check valves, etc.
at a minimum.
Discharge Hose
High pressure pumps require the use of special high pressure
discharge hose (2 rayon braid or equivalent). Use a
hose rated at least 50% greater than the highest operating
pressure required of pump. Example: If required pump pressure
is 200 psi, use discharge hose rated at minimum of 300
psi working pressure.
Unloader Valve
The unloader has a very important safety function in your
piston pump hookup. The unloader valve protects the pump
by unloading pressure when the gun is shut off or discharge
is otherwise blocked. This saves the pump and power
because the liquid is bypassed at a very low pressure. If the
gun is to be shut off for more than 5 minutes, install a pump
protector in the inlet side or stop the pump to prevent heat
buildup. The length of time may vary due to the original temperature
of the fluid being pumped.
Strainers
Use a suction line strainer with at least 3 to 5 times the suction
port area in open screen area. For example, an area of
approximately 1.1 to 1.9 square inches for a 1/2" suction
port. Be sure the screen is suitable for the liquid being
pumped. Keep the filter clean. A clogged strainer will cause
cavitation, which usually leads to a poor performance and
wear of the pump parts.
Pulsation
Dampener
Inlet
Pressure
Regulator
Compound
Gauge
Pump
Filled
Pressure
Gauge
Bypass Back to Inlet
Unloader
Valve
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Spray
Gun
Nozzle
Line
Strainer
-4-
Compound Gauge (Optional)
The pump should not be subjected to high suction line vacuums.
To check on this, install a compound gauge at pump inlet.
For ultimate performance and life, the vacuum should be limited
to 5 inches of mercury. High vacuum conditions may cause
premature product failure and void warranty.
Pulsation Dampener
This device absorbs the shock and smooths out the pump discharge
pulsations, providing smoother operation. For the
proper operation of many unloader valves, the pulsation dampener
should be installed on the discharge side downstream
from the unloader valve. However, for maximum system protection,
the pulsation dampener may be installed upstream
from the unloader valve, provided the unloader valve will function
properly. The dampener can be mounted vertically or
horizontally.
Pressure Regulator
Use a pressure regulator to limit incoming pressure to 20 psi
when equipped with a suction side injector. Volume, pressure
and horsepower figures in pump performance tables do not
apply when incoming pressure exceeds 40 psi.
Pressure Gauge/Dampener
Use gauge capable of reading double the pump working pressure.
Use a silicone-filled gauge or a gauge dampener to protect
the gauge needle against pressure surges and provide
easier reading.
Operation
Priming
If the liquid is below level of the pump, some means
should be provided in installation to prime pump, such
as a foot valve or check valve to hold prime. Keep suction
lift to minimum and avoid unnecessary bends in the
suction line. Before starting pump, make sure air bleeder
valve or spray gun is open, or unloader valve is
adjusted to its lowest pressure. After starting pump,
open and close gun several times if necessary to aid
priming the pump. If pump does not prime within a few
seconds, stop motor and inspect installation for suction
line leaks or obstructions. Make sure that strainer is not
clogged. Be sure that suction line is not obstructed,
kinked or blocked.
If the pump is to operate hours at a time, check frequently
for:
1. Adequate liquid supply. Pump must not run dry for
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more than 30 seconds.
2. Temperature rise. Overheating is harmful to bearings
and piston cups.
NOTE: Models 53702 and 53703 Inlet Requirements:
Pressure feed 20 to 100 psi.
Care of Pump
Your pump will last longer and give best performance
when properly taken care of. Proper pump care
depends on the liquid being pumped and when pump
will be used again. In a normal car wash or detergent
cleaning installation (where each application is followed
by a clear water rinse), the pump will be kept clean.
After each use, flush pump with a neutralizing solution
for the liquid just pumped. Follow with a clear water
rinse. This is especially important for corrosive chemicals.
Then flush out pump with a 50% solution of automotive
ethylene glycol-type radiator antifreeze containing
a rust inhibitor, or use a commercial rust inhibitor
such as FLUID FILM.
While this flushing is not absolutely necessary for short
periods of idleness (as overnight), it is good practice to
clean the pump after each use to prevent deposits from
forming and damaging the pump. The antifreeze not
only coats the interior of the pump with an inhibitor, but
acts as a lubricant as well, keeping valves from sticking
- and protecting against any remaining moisture freezing
in cold weather.
For infrequent use and before long periods of storage,
drain pump thoroughly. Open any drain plugs, remove
suction hose from liquid, and run pump “dry” from 0 to
30 seconds (not longer). Once again, a rust inhibitor
should be injected into the pump before both ports are
plugged and the pump is stored. Then, plug both ports
to keep out air until pump is used again.
Lubrication Schedule
Use a grease gun to lubricate Hypro Series 5300 and
5324 Piston Pumps and Series 5321 and 5322 Plunger
Pumps. DO NOT USE AIR-POWERED GREASE
GUNS as they develop too much pressure and may
cause damage to the sealed cam bearing.
Lubrication
EXCEPTION: In applications where FDA approval is
required, use one of these greases: Chevron FM#2,
Mobile FM#2 Keystone (Penwalt Corp.) Nevastane SP
Medium. Lubricate every 50 hours or monthly.
With a screwdriver or flat tool, apply a generous dab of
grease to outer diameter surface of cam bearing at top
and bottom where bearing contacts connecting rod.
Do not grease excessively.
Check periodically and scrape out (do not WASH out)
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any excess grease from pump cavity.
-5-
Used for Series
Ref. Part No. Description 5321 5324 5300
A 1055-0005 Seal Ring Seating Tool •
B 3010-0052 Valve Cage Extractor • • •
C 3010-0061 Main Bearing Support Tool • • •
D 3010-0063 Cam Bearing Support Tool • • •
E 3010-0064 Support Bars (Qnty 2) • • •
F 3010-0065 Pry Bar • • •
G 3010-0066 Wire Brush • • •
H 3010-0067 Wire Brush Holder • • •
I 3010-0071 Valve Seat Extractor • • •
J 3010-0222 Seal Ring Seating Tool •
K 3020-0001 3/16" Allen Wrench • • •
L 3020-0003 1/8" Allen Wrench • • •
M 3020-0009 1/16" Allen Wrench • • •
Repair Instructions
Recommended Repair Tools
For Hypro Small Twin Piston/Plunger Pumps
Figure 6 Recommended Repair Tools
Recommended Shop Tools
Bench Press, Arbor Press, Air Gun or Electric Hand
Drill, Metal Pipe, Support Fixture, (3" diameter x 4 1/2"
high), Ratchet Handle Wrench with 9/16" Hex Socket,
Bolt (3/8" diameter x 4 1/2" long), No. 320 Grit Emory
Cloth, Pliers, Small Knife, Large File, Claw Hammer,
Standard Screwdriver, Lubricating Spray (WD-40 or
LPS), Wire Brush (hand or machine), Stationary Belt
Sander, and Cleaning Solvent Tank (recommended)
Inspection of Pump Parts
When disassembling pump, thoroughly inspect all
parts and replace if necessary, with special consideration
given to the following areas:
1. Inspect Pump Body for erosion at O-ring seal
points in Valve and Piston bores. Check for wear
resulting from Main Bearings turning in Housing,
especially the Front Bearing area closest to the
Cam Bearing. Check for cracks in the Pump Body,
particularly at the discharge port and along the
casting seam (See Figure 7).
2. Inspect for excessive wear on the Cylinder Heads.
This can result from erosion and/or valve seat
hammer (See Figure 7).
3. Inspect for pitting and general wear in the Unitized
Valves, particularly where the Poppets seal
against the seat. If this area is worn, replace all
four Valves (See Figure 7).
4. Inspect the Connecting Rod. If there is more than
.007" wear in the total space between the
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Connecting Rod and Cam Bearing, the
Connecting Rod should be replaced. This can be
determined using a feeler gauge. The Cam
Bearing should also be inspected as a bad cam
bearing is the most common cause of a damaged
Connecting Rod. A worn Connecting Rod results
in low volume, low pressure, a hammering sound
and the pump running hot (See Figure 8).
5. Inspect Crankshaft Assembly for general wear.
Rotate Cam Bearing and Main Bearings to check
for roughness due to moisture contamination or
lack of grease. If main bearings do not turn
smoothly or appear to be damaged, they should
be replaced. If cam bearing is damaged, a new
Crankshaft Sub-assembly should be installed and
the connecting rod inspected for wear (See Figure
8).
NOTE: Always use new O-rings, Cups, Seal Rings,
Support Rings, Guides, Washers, and Piston Cap
Screws. If new Valves are needed, always replace
the complete set of four.
Figure 7
Figure 8
Use a feeler gauge on
this end to check
amount of space.
Check this area for
wear on both ends.
-6-
Series 5300X, 5321, 5322, & 5324
Disassembly, Repair, & Reassembly Instructions
NOTE: Due to variations in each model's Piston or
Plunger Stack, differences in the instructions for
each model will be denoted with italics and brackets.
HAZARDOUS SUBSTANCE ALERT: Always drain
and flush pump before servicing or disassembly.
Valve Assembly Removal:
1. Place the Pump upright in a bench-mounted vise
with the Safety Cover facing out; then, using a
9/16" wrench, remove the Cylinder Head Bolts.
2. Remove the Cylinder Head.
3. Using a screwdriver or knife, remove the Cylinder
Head O-ring from the Cylinder Head.
4. Using the Seat and Cage End Valve Extraction
Tools, remove the Unitized Valve Assembly from
the Pump Body (See Figures 9 and 10).
Figure 9
Figure 10
To remove Valve Cage.
Hook prongs of Valve
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Cage Extractor under
three webs of the Valve
Cage and pull up with a
twisting motion.
To remove Valve Seat.
Hook Valve Seat Extractor
under Seat and work out
with an up and down
motion.
5. Rotate the Pump Shaft so the Cam Bearing is in
the upstroke position; then using a 3/16’’ Allen
wrench, remove the Cap Screw from the Piston
Assembly for Models 5300X and 5324 [For Models
5321 & 5322, remove the Plunger from the Pump
Body after the Cap Screw is removed].
6. Turn the Pump over and repeat Steps 1 through 5.
7. Position the Pump horizontally in the vise with the
Safety Cover side up.
8. Use a claw hammer to remove the Grease fitting
(See Figure 11). In most cases, the Grease Fitting
is damaged during removal and must be replaced
[At this time, remove the Connecting Rod in
Models 5321 & 5322].
Figure 11
Piston Sleeve Assembly Removal and
Cleanup (5300X and 5324 only)
See Figures 12 & 13 for Piston Stack Components
Cap Screw
Washer
O-ring
Cup Spreader
Cup
Cup Backing Plate
O-ring
Seal Ring
Guide
Figure 12
Cap Screw
Washer
Support Ring
Cup
Cup Holder
O-ring
Seal Ring
Guide
Figure 13
-7-
1. Leave the pump body horizontal in the bench vise
to remove the Cylinder Sleeves and Piston
Assemblies. Make sure the Cam Bearing is in the
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